Carrier 30XA080-500 User manual

Brand: Carrier

Model: 30XA080-500

Category: Split-system air conditioners

Type: User manual

Carrier 30XA080-500 is a minimum load control accessory that reduces chiller capacities below the standard lowest capacity step, providing more precise control of leaving fluid temperature during light load conditions.

This accessory package is for 30XA080-350 unit; two packages are required for 30XA400-500 to accommodate connections for three refrigerant circuits.

The minimum load control solenoid valve in this accessory limits the amount of gas that can be bypassed from the condenser without impacting oil return.

This accessory package is for 30XA080-350 unit; two packages are required for 30XA400-500 to accommodate connections for three refrigerant circuits.

The minimum load control solenoid valve in this accessory limits the amount of gas that can be bypassed from the condenser without impacting oil return.

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Catalog No. 04-53300010-01 Printed in U.S.A. Form 30XA-6SI Pg 1 12-06 Replaces: New

Book 2

Ta b 5 c

Installation Instructions

Part No: 00EFN900002700A, 00EFN900002800A, 00EFN900002900A

SAFETY CONSIDERATIONS

Installing, starting up, and servicing air-conditioning equip-

ment can be hazardous due to system pressures, electrical com-

ponents, and equipment location.

Only trained, qualified installers and service technicians

should install, start up, and service this equipment.

When working on air-conditioning equipment, observe

precautions in the literature and on tags, stickers, and labels at-

tached to the equipment.

Follow all safety codes. Wear safety glasses and work

gloves. Use care in handling equipment.

GENERAL

This control accessory reduces 30XA chiller capacities be-

low the standard lowest capacity step. This capacity reduction

provides more precise control of leaving fluid temperature

during light load conditions.

The minimum load control solenoid valve limits the amount

of gas that can be bypassed from the condenser without

impacting oil return.

One accessory package is required for 30XA080-350 units.

Two accessory packages are required for 30XA400-500 units

to accommodate connections for three refrigerant circuits. See

Table 1 for accessory package usage.

Table 1 — Accessory Package Usage

INSTALLATION

Examine the package contents for correct part numbers. If

any of the components are damaged, file a claim with the

shipping company and notify your Carrier representative.

See Table 2A, 2B, or 2C for package contents. See Fig. 1 for

dimensional drawings of tubes included in the kit.

The following material is field supplied:

•

in. OD copper tubing

•

in. OD copper tube elbows and couplings

(as required)

• Loctite 554 thread sealing compound

• Parker Super O-lube O-ring lubricant

Install the Solenoid Valve Tube Assembly

1. Remove refrigerant charge from the circuits using an

approved refrigerant recovery device before proceeding

with this installation. Follow good piping practices.

2. Locate the discharge manifold for minimum load

piping on the side of the coil V for each circuit as

shown in Fig. 2. Locate the

in. NPT pipe plugs on

the top of the cooler for each circuit. See Fig. 3.

3. Remove the

in. NPT pipe plugs from the top of the

cooler. Use the thread sealing compound and install

one 1 in.-14 O-ring seal (ORS) x

in. NPT adapter

for each circuit. Lightly lubricate each O-ring with

O-lube and attach the tube assembly to each adapter.

See Fig. 3. Be sure to attach the correct tube assembly

to the cooler. Refer to the usage column in Tables 2A,

2B, and 2C for tube assembly part number correspond-

ing to the unit size and circuit. The nut on the tube

assembly should be torqued to 30 ft-lb (40 N-m).

4. Remove the trim panel on the discharge manifold for

minimum load piping on the side of the coil V. Use a

tubing cutter to cut 1

in. out from the discharge mani-

fold for each circuit. See Fig. 4. Braze a tee in between

the gap and, depending on the routing of the hot gas

bypass tubing, have the tee’s remaining port facing either

left or right.

5. Use field-supplied

in. OD copper tubing and fittings

(as required) to pipe from the solenoid valve outlet to the

in. port of the tee on the discharge manifold. Use the

provided

in. tubing clamps to secure the tubing to the

unit frame as necessary.

6. When piping is completed, leak test the assembly.

7. Evacuate, dehydrate, and recharge each circuit. Be sure to

use the correct type and amount of refrigerant listed in the

nameplate data and base unit documentation.

8. Restore power to the unit.

Be sure power to equipment is shut off before performing

maintenance or service to avoid electrocution. Lock out

and safety-tag all disconnects. There may be more than one

disconnect.

30XA UNIT SIZE ACCESSORY PART NO.

080-240 00EFN9000002700A

260-300 00EFN9000002800A

325, 350 00EFN9000002900A

400

00EFN9000002700A,

00EFN9000002800A

450, 500

00EFN9000002800A,

00EFN9000002900A

30XA080-500

Minimum Load Control Accessory

Table 2A — Contents of Accessory Kit, Part No. 00EFN900002700A

LEGEND

Table 2B — Contents of Accessory Kit, Part No. 00EFN900002800A

LEGEND

PART NUMBER QUANTITY DESCRIPTION USAGE

00PSN500171700A 2

Tube assembly including solenoid valve,

ball valve, and 90 degree bend tube assembly

One per circuit (circuit A and B for 30XA400).

Cooler shell minimum load port, connect to

30GX5034892 adapter.

30GX5034892 2 1 in. -14 ORS x

in. NPT adapter One per circuit. Cooler shell minimum load port.

00PPG000011600A 2 Solenoid coil assembly

One per circuit. Plug onto solenoid valve stub

on 00PSN500171700A tube assembly.

KA66AA062 4

in. tube clamp

Secure minimum load piping to the frame

as required.

DE40BA705 21

in. x 1

in. x

in. Tee

One per circuit. Discharge manifold on the side

of condenser coil V.

TH70400410 2 Cable assembly

One per circuit. Connect to solenoid coil

assembly and terminal block TB5 in control box.

00PPN500000401A 4 No. 10 Screw Mount tube clamps

32GB500432E 1 HGBP/Pump board Mount in control box

TH70400864 1 Harness assembly Wiring between TB5 and HGBP/Pump board

HH83ZB001 1 24 v circuit breaker (CB14) Mount on display bracket in control box

A6X10004352 4 No. 8 screw Mount HGBP/Pump board

A6X10004434 4 Board mounting standoff

Mount HGBP/Pump board (30XA140-240,400:

all voltages and 30XA080-120: 200/230 v, 380 v)

TH70400852 1 Communication cable assembly

30XA140-240,400: all voltages and

30XA080-120: 200/230 v, 380 v

HY89TB010 3Wire nut

Splice communication cable

(30XA080-120: 460 v, 575 v)

HGBP — Hot Gas Bypass

ORS — O-Ring Seal

TB — Terminal Block

PART NUMBER QUANTITY DESCRIPTION USAGE

00PSN500171700A 2

Tube assembly including solenoid valve,

ball valve, and 90 degree bend tube assembly

One per circuit (circuit A and B for 30XA400).

Cooler shell minimum load port, connect to

30GX5034892 adapter.

30GX5034892 2 1 in. -14 ORS x

in. NPT adapter One per circuit. Cooler shell minimum load port.

00PPG000011600A 2 Solenoid coil assembly

One per circuit. Plug onto solenoid valve stub

on 00PSN500171700A tube assembly.

KA66AA062 4

in. tube clamp

Secure minimum load piping to the frame

as required.

DE40BA705 21

in. x 1

in. x

in. Tee

One per circuit. Discharge manifold on the side

of condenser coil V.

TH70400410 2 Cable assembly

One per circuit. Connect to solenoid coil

assembly and terminal block TB5 in control box.

00PPN500000401A 4 No. 10 Screw Mount tube clamps

32GB500432E 1 HGBP/Pump board Mount in control box

TH70400864 1 Harness assembly Wiring between TB5 and HGBP/Pump board

HH83ZB001 1 24 v circuit breaker (CB14) Mount on display bracket in control box

A6X10004352 4 No. 8 screw Mount HGBP/Pump board

A6X10004434 4 Board mounting standoff

Mount HGBP/Pump board (30XA260-300,400,450,

500: all voltages)

TH70400852 1 Communication cable assembly 30XA260-300,400,450,500: all voltages

HY89TB010 3 Wire nut Splice communication cable

HGBP — Hot Gas Bypass

ORS — O-Ring Seal

TB — Terminal Block

Table 2C — Contents of Accessory Kit, Part No. 00EFN900002900A

LEGEND

PART NUMBER QUANTITY DESCRIPTION USAGE

00PSN500175200A 2

Tube assembly including solenoid valve,

ball valve, and 90 degree bend tube assembly

One per circuit (Circuit A and B for 30XA325, 350,

circuit A and C for 30XA450, 500). Cooler shell

minimum load port, connect to 30GX5034892 adapter.

30GX5034892 2 1 in. - 14 ORS x

in. NPT adapter One per circuit. Cooler shell minimum load port.

00PPG000011600A 2 Solenoid coil assembly

One per circuit. Plug onto solenoid valve stub

on 00PSN500171700A tube assembly.

KA66AA062 4 5/8 in. tube clamp

Secure minimum load piping to the frame

as required.

DE40BA705 21

in. x 1

in. x

in. Tee

One per circuit. Discharge manifold on the side

of condenser coil V.

TH70400410 2Cable assembly

One per circuit. Connect to solenoid coil

assembly and terminal block TB5 in control box.

00PPN500000401A 4 No. 10 screw Mount tube clamps

32GB500432E 1 HGBP/Pump board Mount in control box

TH70400864 1 Harness assembly Wiring between TB5 and HGBP/Pump board

HH83ZB001 1 24V circuit breaker (CB14) Mount on display bracket in control box

A6X10004352 4 No. 8 screw Mount HGBP/Pump board

A6X10004434 4 Board mounting standoff

Mount HGBP/Pump board (325,350,450,500:

all voltages)

TH70400852 1 Communication cable assembly 30XA325,350,450,500: all voltages.

HY89TB010 3 Wire nut Splice communication cable

HGBP — Hot Gas Bypass

ORS — O-Ring Seal

TB — Terminal Block

BALL VALVE

SOLENOID VALVE

TUBE ASSEMBLY 00PSN500175200A

SOLENOID VALVE

BALL VALVE

TUBE ASSEMBLY 00PSN500171700AA

NOTE: Dimensions are in mm [in.].

Fig. 1 — Dimensions of Tube Assemblies Provided in Accessory Kit

a30-4499

a30-4500

TTTT

CKT A

CKT B

UNIT SIZE: 260, 280, 300 UNIT SIZE: 220, 240

CKT BCKT A

CKT A

CKT B

UNIT SIZE: 180, 200

UNIT SIZE: 325, 350

CKT A

CKT B

CKT C

CKT A

CKT B

UNIT SIZE: 400 UNIT SIZE: 140, 160

CKT A

CKT B

CKT C

CKT A

CKT B

UNIT SIZE: 450, 500

CKT A CKT B

UNIT SIZE: 080

CKT A

CKT B

UNIT SIZE: 090-120

Fig. 2 — Discharge Manifold Location for Minimum Load Piping Per Circuit

LEGEND

NOTES:

1. Diagrams view 30XA from the cooler side.

2. Shaded area denotes the location of manifolds.

CB — Control Box

CKT — Circuit

T—Tee (braze tee in this dis-

charge manifold location)

a30-4498

B CIRCUIT

A CIRCUIT

1/2 IN. NPT

TUBE ASSEMBLIES

CUT 1-1/2 IN. OFF THE DISCHARGE MANIFOLD

BRAZE THE TEE IN THIS LOCATION

REMOVE TRIM PANEL

TO ACCESS

Fig. 3 — Typical Solenoid Valve Tube Assembly Installation

Fig. 4 — Discharge Manifold Modification and Tee Brazing

a30-4501

a30-4502

Install HGBP/Pump Board and Control Wiring

1. Attach the solenoid coil assembly to the solenoid valve

plunger on the tube assembly for each circuit. One cable

assembly TH70400410 is supplied per circuit. Secure the

DIN connector end on the solenoid valve coil with the

screw in the connector. Verify the square rubber gasket is

in place to ensure connection remains watertight.

2. Route the other end of the cable to the main control panel

(where the display is located). For the circuit A solenoid,

connect leads to TB5-7 and TB5-13. For the B circuit

solenoid, connect leads to TB5-8 and TB5-13. For the C

circuit solenoid (30XA400-500 only), connect the leads

to TB5-6 and TB5-13. In all cases, the black wire from

the solenoid must be connected to TB5-13 to ensure

correct polarity.

3. Set the board address of the HGBP/Pump Board by posi-

tioning the dual in-line package (DIP) switches to the

correct settings. See Fig. 5. Mount the HGBP/Pump board

in the main control panel with the No. 8 screws provided

(mounting standoffs required for 30XA080-120: 200 v,

230 v, 380 v and 30XA140-500: all voltages). See Fig. 6A

and 6B for the board mounting location.

4. Mount the 24-v circuit breaker (CB14) in the CB14

mounting hole on the display bracket. See Fig. 6A and 6B

for the mounting hole location.

5. Connect the 24-v power from TB10-X1 (30XA080-120:

460 v, 575 v only) or TB11-X1 (30XA080-120: 200/230 v

and 30XA140-500: all voltages) to CB14 with the

provided red wire in the harness assembly. Find two 2-pin

plugs marked J1-11,12 with red and brown wires in the

harness assembly. Connect the plug to the HGBP/Pump

board J1 with the red wire connected to CB14 and the

brown wire connected to TB10-X2 (30XA080-120: 460 v,

575 v only) or TB11-X2 (30XA080-120: 200/230 v and

30XA140-500: all voltages). See Fig. 7.

6. Using harness TH70400864 provided in the kit, connect

TB5 pins 6 (30XA400-500 only), 7, 8, and 13 to HGBP/

Pump board J2 CH3, CH4 and J3 CH5 (30XA400-500

only). Use the pins inside TB5. See Fig. 5.

7. For 30XA080-120: 200/230 v, 380 v and 30XA140-500:

all voltages, disconnect the 3 pin plug on MBB J9B (or

EMM board J9A) for communication and plug it in to the

HGBP/Pump board J9. Use the additional communica-

tion cable assembly TH70400852 provided in the kit to

connect between HGBP/Pump board J9 and MBB J9B

(or EMM board J9A when EMM board exists). The com-

munication cable in the TH70400864 harness will not be

used. For 30XA080-120: 460 v, 575 v, connect the 3 pin

plug of the communication cable in the TH70400864

harness to the HGBP/Pump board J9 and splice the other

end of the cable to the communication network using the

wire nuts provided in the kit. Be sure to splice the wires

with same color together to ensure correct polarity.

Take care connecting leads to terminal blocks. Incorrect

polarity will damage the control boards.

a30-4503

Fig. 5 — HGBP/Pump Board Address Switch and

Wiring for Minimum Load Solenoid Output

HGBP/PUMP

BOARD

CB14

Fig. 6A — HGBP/Pump Board and CB14 Mounting Location

(30XA080-120: 200 v, 230 v, 380 v and 30XA140-500: all voltages)

a30-4504

TB10-X2 OR TB11-X2

TB10-X1 OR TB11-X1

RED

BRN

CB14

3.2 AMPS

BRN

RED

FIOP/ACCESSORY

HGBP/

PUMP

BOARD

Fig. 6B — HGBP/Pump Board and CB14 Mounting Location

(30XA080-120: 460 v, 575 v)

Fig. 7 — HGBP/Pump Board 24 v Power Wiring

a30-4506

TOUCH

PILOT

DISPLAY

CB14

HGBP/PUMP

BOARD

a30-4505

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Catalog No. 04-53300010-01 Printed in U.S.A. Form 30XA-6SI Pg 8 12-06 Replaces: New

Book 2

Ta b 5 c

Configure Unit for Minimum Load Control —

The controls must be configured for the minimum load control

operation. Use the Touch Pilot™ or the Navigator™ display to

configure the system. Refer to the 30XA Controls, Start-Up,

Operation, Service, and Troubleshooting manual for additional

information.

Complete the following steps to configure minimum load con-

trol with the Touch Pilot display:

1. Ensure the unit is in Local Off operating mode by looking

at the upper left hand corner of the group display. If the

unit is not in Local Off mode, press the Start/Stop button

to switch to the Local Off operating mode.

2. Press the main menu button on the bottom line of the

display, and then select Service→ Factory to navigate to

the factory table.

3. Scroll down the screen by pressing the Scroll Down

button or the Page Down button until Hot Gas

Bypass Select is displayed on the screen. Press Hot Gas

Bypass Select to display the Point Data dialog.

4. Press the Modify button . If the login menu is dis-

played, log in with the password. The default password is

3333. Press the OK button to confirm the input. The

value of hgbp_sel will display. Select Yes and press

the OK button to confirm the input.

5. Press the Home button on the bottom line of the dis-

play. A save confirmation menu will display. Press the

OK button to confirm the action.

6. Wait 10 seconds and cycle the control power using the

Emergency On/Off switch (SW2).

The chiller is now configured for minimum load valve control.

Complete the following steps to configure minimum load con-

trol with the Navigator display:

1. Set the Enable/Off/Remote switch to the Off position.

2. Press until the screen is blank and use the

arrow key to select the Configuration mode LED.

3. Press , then use the arrow key to select the

sub-mode ‘UNIT’, then press the key.

4. Press the down arrow key until ‘HGBP’ is displayed.

5. Press the key. If the login menu is displayed,

Use the arrow keys to change each number’s value. Press

the key after each number until finished.

6. Press the key so that ‘No’ flashes.

7. Use the arrow keys to change the value to ‘Yes.’

8. Press the key.

9. Press the key until ‘DISP’ is displayed. Wait

10 seconds and cycle the control power using the Emer-

gency On/Off switch (SW2).

The chiller is now configured for minimum load valve control.

Test Minimum Load Relay Output — Use the Touch

Pilot or Navigator display’s service test mode and the instruc-

tions given in their Controls, Start-Up, Operation, Service, and

Troubleshooting manuals to verify proper operation of the

solenoid(s).

For the Touch Pilot display:

1. Ensure the unit is in Local Off operating mode by looking

at the upper left hand corner of the group display. If the

unit is not in the Local Off mode, press the Start/Stop but-

ton to switch to the Local Off operating mode.

2. Press the Main Menu button on the bottom line of

the display and then select Status→ Quick Test Enable.

3. Press the Force button . If the login menu is dis-

played, log in with the password. The default password is

3333. Press the OK button to confirm the input.

4. The value of qck_test1 will display. Select On and press

the OK button to confirm the input.

5. Scroll down the screen by pressing the scroll down button

or the page down button until Cir. A Hot Gas

Bypass is displayed on the screen. Press Cir. A Hot Gas

Bypass Select to display the Point Data dialog.

6. Press the Force button . Select On and press the OK

button to confirm input.

7. Verify that the Cir. A minimum load valve (MLV) sole-

noid is energized.

8. Proceed to Cir. B Hot Gas Bypass and Cir. C Hot Gas By-

pass (30XA400-500 only) by pressing the page down

button . Repeat Steps 5-7 for Cir. B MLV and Cir. C

MLV.

9. Use the page up button to return to the top of the ta-

ble and select Quick Test Enable.

10. Press the Force button .

11. Select Off and press the OK button to disable Quick

Test.

12. Once the outputs have been tested, the installation is com-

plete. Return the Touch Pilot to Local Off operating

mode.

For the Navigator display:

1. Set the Enable/Off/Remote switch to the Off position.

2. Press until the screen is blank and use the

arrow key to select the Service Test mode LED.

3. Press , then use the arrow key to select the

sub-mode ‘QUIC’, then press the key.

4. Press the down arrow key until ‘HGP.A’ is displayed.

5. Press the key. If the login menu is displayed,

Use the arrow keys to change each number’s value. Press

the key after each number until finished.

6. Press the key so that ‘Off’ flashes.

7. Use the arrow keys to change the value to ‘On.’

8. Press the key.

9. Verify that the Cir. A minimum load valve (MLV)

solenoid is energized.

10. Proceed to ‘HGP.B’ and ‘HGP.C’ (30XA400-500 only)

and repeat Steps 4-9 for Cir. B MLV and Cir. C. MLV.

11. Once the outputs have been tested, the installation is com-

plete. Return the Enable/Off/Remote contact switch to the

desired position.

ESCAPE

ENTER

ESCAPE

ENTER

Carrier 30XA080-500 User manual

Brand: Carrier

Model: 30XA080-500

Category: Split-system air conditioners

Type: User manual

This accessory package is for 30XA080-350 unit; two packages are required for 30XA400-500 to accommodate connections for three refrigerant circuits.

The minimum load control solenoid valve in this accessory limits the amount of gas that can be bypassed from the condenser without impacting oil return.

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Carrier 30XA080-500 User manual

Carrier 30XA080-500 User manual

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